Simulation, part path correction, and automated process parameter selection for ultrashort pulsed laser micromachining of sapphire

This dissertation describes an ultrashort pulsed laser material removal simulator with X-Y stage acceleration profile consideration and part path compensation. Ultrashort pulsed lasers offer the advantage of single step processing of various materials with high repeatability. Over the past 30 years the laser repetition rate and power output have increased, and although this increases the material removal rate, it also introduces new challenges. The acceleration rates of the X-Y stages on a laser micromachining setup are finite, but this has been neglected. In the past the acceleration rate has been negligible due to low repetition rates; however, for high repetition rates the acceleration and deceleration regions introduce local variations in the material removal. A novel method is presented that accounts for the stage dynamics to produce a more robust simulated cut.;In addition to the simulator, a technique for modifying the part path to reduce non-uniformity in the material removal is discussed. The laser operator has access to a variety of process parameters that ultimately affect the cost and quality of the machined component. Choosing the correct combination of these parameters requires knowledge of the machining process, and the wrong combination can result in a feature that is unsatisfactory and/or overly expensive. The modification of these parameters, and a correction of the part path allows for a more uniform depth of cut and higher feature quality.;This dissertation contains three main contributions. The first contribution is to quantify the relationship between ultrashort pulsed laser machining parameters and the ablation depth of sapphire. The second is to produce a pulsed laser micromachining simulator that includes not only the laser-material interaction, but also the nuances of controlling the position of the laser beam on the workpiece. The final contribution is to produce a part path correction program with an automated process parameter routine. This program simplifies the process parameter selection and reduces depth irregularities in the machined geometry.;Ultrashort pulsed lasers are a relatively new laser type; consequently, there is a plethora of aspects that may be added into future iterations of the simulator, automated parameter selection routine, and part path correction software. These aspects include, but are not limited to: sidewall angle compensation, thermal diffusion modeling, and modeling of additional workpiece materials.